We then cut thousands of pieces from more than a hundred sheets of three quarter inch plywood on our MultiCam CNC router. These plywood pieces were bolted to welded steel frames.
The decorative inserts and signs were dimensionally routed from 30 lb Precision Board. They were mounted to the plywood. Galvanized lath was stapled to the plywood and then a thick coat of fibreglass reinforced concrete was troweled on and sculpted to look like wood, bricks, stone and plaster.
Then the painting crew worked their magic, first with three base coats of paint, followed by the glazing and dry brushing.
Today we welded up the last of the large steel pallets and fasted the giant posts to them in pairs. In the next couple of days we will load the last pieces for this phase of the project into the semi trailer and send them on their way.